Energy and Thermal Considerations in Weld System Development

This paper provides a means of estimating the energy distribution during a resistance weld between a round wire and a ribbon. It also shows that energy considerations are not adequate to predict the success of a weld system and that a consideration of the thermal nature of the materials involved is required to achieve a satisfactory heat balance. A ratio of physical properties is provided that can be used to predict the compatibility of a wire and ribbon before the extensive process of weld schedule development and qualification is begun.